Hairpin Winding Stator Layout for Insulation and Coil Simplification
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Solution Overview
Problem
Existing hairpin drive motors face insulation issues due to adjacent hairpin phases with minimal pitch, leading to poor insulation performance, and the complexity of coil winding operations is increased by the use of flat coils with high rigidity.
Innovation Solution
A stator assembly design with reduced anomalous coils, where main coils are positioned in inner and outer layers, and anomalous coils are strategically placed in intermediate layers, minimizing phase differences and improving insulation by reducing the number of anomalous coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of turns of the coil is increased to improve motor output, then the output increases, but the size of the stator core or motor inevitably increases
Solution Approach 1:
The patent changes the geometric parameters of the coil from circular cross-section to square cross-section, and optimizes the winding configuration parameters (number of layers, turns per layer, pitch) to increase the space factor of the coil without increasing the stator core size, thereby improving motor output while maintaining compact dimensions
2Power
If flat coil is used to increase space factor and improve motor output, then the space factor increases, but the coil winding operation becomes more difficult due to increased rigidity
Solution Approach 1:
The patent segments the coil winding into multiple layers with different configurations (first layer with certain pitch, second layer with different pitch), allowing each layer to be wound more easily while achieving high space factor overall, thus resolving the contradiction between rigidity and manufacturability
3Volume of stationary object
If minimal pitch between adjacent hairpin phases is used, then the space utilization improves, but the insulation performance deteriorates due to adjacent phases with minimal pitch
Solution Approach 1:
The patent applies different pitch values to different layers locally: the first layer uses a first pitch while the second layer uses a second pitch different from the first, creating local variations in phase arrangement that prevent adjacent phases from having minimal pitch throughout, thereby maintaining both space utilization and insulation performance
Data Source
AI summary
A stator assembly includes a stator core including a plurality of slots configured to penetrate through the stator core in a circumferential direction, each of the slots including a plurality of layers in a radial direction; and a plurality of hairpin coils configured to fasten and interconnect to the slots, respectively, to form a coil winding. The hairpin coils include a main coil having a first slot pitch, an anomalous coil having a second slot pitch different from the first slot pitch, and a leader coil. In each of the slots, the main coil is disposed in each of a radially innermost layer of the layers, a radially outermost layer of the layers, and an intermediate layer of the layers between the innermost layer and the outermost layer. The leader coil is disposed in each of the innermost layer and the outermost layer.